Thermally insulated stud and methods for producing the same

ABSTRACT

A thermally insulated stud and methods for producing the same. First and second elongated structural members are placed vertically parallel to one another, defining a space therebetween. The space is filled with a thermally insulative material, providing reduced thermal conductivity in a horizontal direction through the stud.

TECHNICAL FIELD

The present invention relates to construction materials, and more particularly, to an insulated stud and methods for producing the insulated stud.

BACKGROUND OF THE INVENTION

A typical structural member used in construction is a single length of wood as grown in the forest that has been trimmed to the desired dimensions. While such structural members have served for centuries in the construction of homes and other buildings, today's greater demand for heating and cooling efficiency has affected the choice of building materials. Materials having high thermal insulation values are currently being used in construction walls and roofs, but the search for other substitutes is continual.

One area which has not been affected much by this search for thermal efficiency is that of studs that are used as structural members that vertically support entire building structures. Some new laminated studs made from recycled or waste forestry products and modern glues and adhesives are used, but they are expensive and heavy. It is still desirable to have a thermally-insulated stud which is light and yet equal in strength to a wood stud.

SUMMARY OF THE INVENTION

According to one aspect, the invention is an elongated stud for supporting a vertical load.

The elongated stud includes a first elongated structural member having a vertical longitudinal axis and a second elongated structural member having a vertical longitudinal axis that is parallel to the vertical longitudinal axis of the first elongated structural member. The first and second elongated structural members are separated from each other and define a space therebetween.

A thermally insulative member fills the space between the first and second elongated structural members. The thermally insulative member provides thermal insulation against heat flow in a horizontal direction.

According to a second aspect, the invention is a method for making an elongated stud for supporting a vertical load.

The method includes the steps of: a) forming a first elongated structural member having a vertical longitudinal axis; b) forming a second elongated structural member having a vertical longitudinal axis; and c) placing the first and second elongated structural members so that their vertical longitudinal axes are parallel and there is a space defined therebetween. The method also includes the step of d) filling the space between the first and second elongated structural members with a thermally insulative material thereby forming a thermally insulative member that provides thermal insulation against heat flow therethrough in a horizontal direction.

According to a third aspect, the invention is an apparatus for making an elongated stud for supporting a vertical load.

The apparatus includes means for forming a first elongated structural member having a vertical longitudinal axis, means for forming a second elongated structural member having a vertical longitudinal axis, and means for placing the first and second elongated structural members so that their vertical longitudinal axes are parallel and there is a space defined therebetween, and

means for filling the space between the first and second elongated structural members with a thermally insulative material thereby forming a thermally insulative member that provides thermal insulation against heat flow therethrough in a horizontal direction.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective views of a first preferred embodiment of the thermally-insulative stud of the present invention.

FIG. 2 is a second perspective view of a first preferred embodiment of the thermally-insulative stud of the present invention.

FIG. 3 is a side elevation view of an end of the first preferred embodiment of the thermally-insulative stud of the present invention.

FIG. 4 is a side elevation view of the opposite side of the first preferred embodiment of the thermally-insulative stud of the present invention.

FIG. 5 is a top view of an end of the first preferred embodiment of the thermally-insulative stud of the present invention.

FIG. 6 is a bottom view of an end of the first preferred embodiment of the thermally-insulative stud of the present invention.

FIG. 7 is a front view of the first preferred embodiment of the thermally-insulative stud of the present invention.

FIG. 8 is a back view of the first preferred embodiment of the thermally-insulative stud of the present invention.

FIG. 9 is a perspective view of an end of a second preferred embodiment of the thermally-insulative member of the present invention.

FIG. 10 is a perspective view of an end of a third preferred embodiment of the thermally-insulative member of the present invention.

FIG. 11 is a perspective view of a fourth preferred embodiment of the thermally-insulative member of the present invention.

FIG. 12 is a perspective view of a fifth preferred embodiment of the thermally-insulative member of the present invention.

FIG. 13 is a perspective view of a sixth preferred embodiment of the thermally-insulative member of the present invention.

FIG. 14 is a perspective view of a seventh preferred embodiment of the thermally-insulative member of the present invention.

FIG. 15 is a perspective view of an eighth preferred embodiment of the thermally-insulative member of the present invention.

FIG. 16 is a perspective view of a ninth preferred embodiment of the thermally-insulative member of the present invention.

FIG. 17 is a perspective view of a tenth preferred embodiment of the thermally-insulative member of the present invention.

FIG. 18 is a perspective view of an eleventh embodiment of the thermally-insulative member of the present invention.

FIG. 19 is a perspective view of a twelfth embodiment of the thermally-insulative member of the present invention.

FIG. 20 is a perspective view of a thirteenth embodiment of the thermally-insulative member 40′ of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT OF THE INVENTION

FIGS. 1 and 2 are perspective views of a first preferred embodiment of the thermally-insulative stud of the present invention. FIG. 3 is a side elevation view of an end of the first preferred embodiment of the thermally-insulative stud of the present invention, and FIG. 4 is a side elevation view of the opposite side of the first preferred embodiment of the thermally-insulative stud of the present invention. FIG. 5 is a top view of an end of the first preferred embodiment of the thermally-insulative stud of the present invention, and FIG. 6 is a bottom view of an end of the first preferred embodiment of the thermally-insulative stud of the present invention. FIG. 7 is a front view of the first preferred embodiment of the thermally-insulative stud of the present invention and FIG. 8 is a back view of the first preferred embodiment of the thermally-insulative stud of the present invention. The thermally-insulative stud 40 is intended primarily for supporting a downward vertical load, such as the weight borne by a stud in structure construction, although it can also support an upward vertical load.

The thermally insulative stud 40 includes a first elongated structural member 42, a second elongated structural member 44, and a thermally-insulative member 46. The first and second elongated structural members 42 and 44 are each made from a single integral piece of material. If the material is a sheet metal, such as galvanized steel or aluminum, the first and second elongated structural members 42 and 44 are formed by properly bending the sheet. A 16 gauge sheet metal has been found suitable for many applications, although other gauges can be chosen as desired. If the material is a formed material, such as fiberglass or carbon fiber composites, the first and second elongated structural members 42 and 44 are shaped properly before their shape is set by some further action, such as a thermal or chemical reaction.

The first and second elongated structural members 42 and 44 have respective first and second axes 48 and 50, and, in use, the first and second elongated structural members 42 and 44 are placed so that the respective first and second axes 48 and 50 are vertical. Furthermore, the first and second elongated structural members 42 and 44 are placed so that there is a space 52 therebetween. In some embodiments, the first and second elongated structural members 42 and 44 are touching, whereas in some other embodiments, the first and second elongated structural members 42 and 44 are not touching. However, the space 52 is generally limited to the volume defined between the first and second elongated structural members 42 and 44.

The thermally-insulative member 46 is formed or placed in the space 52 and in contact with the first and second elongated structural members 42 and 44. The placement is set so that the first and second elongated structural members 42 and 44 each extend horizontally toward one another and relative to the thermally-insulative member 46. The thermally-insulative member 46 is formed from any material having a suitable thermal insulation value. Preformed blocks made from expanded or extruded polystyrene are suitable, although polyethylene polyisocyhalrite and polyurethane are also suitable plastics. Other insulative materials such as a mixture of mud and straw are also suitable for some applications. However, it is preferable to form the thermally-insulative member 46 within the space 52 so that it adheres to the interior surfaces of the first and second elongated structural members 42 and 44.

In the first preferred embodiment shown in FIGS. 1-8, the first and second elongated structural members 42 and 44 are channels, formed by bending a length of galvanized sheet steel along two parallel lines to form edges 54. The first elongated structural member 42 includes a web 56 that extends between a first leg 58 and a second leg 60. Similarly, the second elongated structural member 44 includes a web 62 that extends between a first leg 64 and a second leg 66. The web 62 is parallel to the web 56, and the first legs 58 and 64 and the second legs 60 and 66, respectively extend toward one another. Depending upon the lengths of the first and second legs 64 and 66 relative to the web 62, the channels can be characterized as C- or U-channels, with U-channels having first legs 58 and second legs 60 that are longer than the web 62.

The thermally-insulative member 46 has a vertical dimension that is equal, or very nearly equal, to the vertical dimensions of the first and second elongated structural members 42 and 44. The horizontal dimensions of the thermally-insulative member 46 are such that the thermally-insulative member 46 substantially fills the space between the first and second elongated structural members 44 and 46. As a result, if the first and second elongated structural members 42 and 44 do not touch, a portion of the thermally-insulative member 46 is exposed between the two first legs 58 and 64 and between the two second legs 60 and 66.

The first and second elongated structural members 42 and 44 support the load applied to the stud 40, and the thermally-insulative member 46 substantially increases the overall thermal insulation value of the stud 40, including in the horizontal direction. The stud 40 can be built in any desired dimensions. However, the vertical height of the stud 40 is typically 8 or more feet, while the width of the stud 40 is typically 3.5 and 5.5 inches.

Where the following embodiments are substantially similar to the first embodiment, their features which are the same as those of the first embodiment will be given the same reference numerals, but will be used only if necessary to describe their differences from the first embodiment.

FIG. 9 is a perspective view of an end of a second preferred embodiment of the thermally-insulative member of the present invention. The second preferred embodiment of the thermally-insulative stud 40 is substantially similar to the first preferred embodiment described in FIGS. 1-8, except that the second elongated structural member 44 is turned 180 degrees about its vertical axis 50 as compared to the embodiment in FIGS. 1-8. The first elongated structural member 42 has an aperture 68, as is conventional with metal studs. The space 52 is defined between the first and second elongated structural members 42 and 44, and is substantially filled with a thermally-insulative member 46 (not shown).

FIG. 10 is a perspective view of an end of a third preferred embodiment of the thermally-insulative member of the present invention. The third preferred embodiment is made from two separated C-channels which serve as the first and second elongated structural members 42 and 44 and whose legs are directed to the legs of the other C-channel. The space 52 between the first and second elongated structural members 42 and 44 is substantially filled with a thermally-insulative member 46 (not shown).

FIG. 11 is a perspective view of a fourth preferred embodiment of the thermally-insulative member of the present invention. The fourth preferred embodiment of the thermally-insulative stud 40 of the present invention is substantially the same as the first preferred embodiment of the thermally-insulative stud 40 shown in FIGS. 1-8. However, the fourth preferred embodiment shows the first and second elongated structural members 42 and 44 with their respective first legs 58 and 64 and second legs 60 and 66 directed away from one another. The space 52 between the first and second elongated structural members 42 and 44 is substantially filled with a thermally-insulative member 46 (not shown).

FIG. 12 is a perspective view of a fifth preferred embodiment of the thermally-insulative member of the present invention. The fifth preferred embodiment of the thermally-insulative stud 40 of the present invention is substantially the same as the first preferred embodiment of the thermally-insulative stud 40 shown in FIGS. 1-8. However, the two C-channels (elongated structural members 42 and 44) are touching along the seams 80, which may be stitch welded or otherwise connected to hold the first and second elongated structural members 42 and 44 together as a unit. The first and second elongated structural members 42 and 44 define the space 52, which is substantially filled with a thermally insulative member 46 (not shown).

In addition, a sheet of material 82 can be attached to one of the faces of the combined first and second elongated structural elements 42 and 44 (such as that composed of the first legs 58 and 64, the second legs 60 and 66, the web 56 or the web 62). The sheet of material 82 could be insulative, structural, fireproofing, or decorative. For example, the sheet of material 82 could be made from ⅛″ cement board or a veneer, or even from a paintable or otherwise appliable coating, as will be known by those skilled in the relevant arts. The sheet of material 82 can be applied to any of the preferred embodiments of the thermally-insulative member of the present invention that are disclosed in the foregoing or following detailed descriptions, or to any equivalents that would be known by those skilled in the relevant arts.

FIG. 13 is a perspective view of a sixth preferred embodiment of the thermally-insulative member of the present invention. In this embodiment, the first elongated structural member 42 is an elongated rectangular sheet of material and the second elongated structural member 44 is an elongated U-channel. Alternatively, the first elongated structural member 42 can be connected to the second elongated structural member 46 by means such as conventional fasteners or stitch welding. The first and second elongated structural members 42 and 44 define the space 52, which is substantially filled with a thermally insulative member 46 (not shown).

FIG. 14 is a perspective view of a seventh preferred embodiment of the thermally-insulative member of the present invention. In this embodiment, the first elongated structural member 42 is an elongated rectangular sheet of material and the second elongated structural member 44 is an elongated C-channel. Alternatively, the first elongated structural member 42 can be connected to the second elongated structural member 46 by means such as conventional fasteners or stitch welding. The first and second elongated structural members 42 and 44 define the space 52, which is substantially filled with a thermally insulative member 46 (not shown).

FIG. 15 is a perspective view of an eighth preferred embodiment of the thermally-insulative member of the present invention. The first elongated structural member 42 is an elongated channel (either a C-channel or a U-channel, or other known variants) and the second elongated structural member 44 is a box member (either square or rectangular cross-section, or other known variants). The first and second legs 58 and 60 are directed toward and either spaced apart from, or contacting, the second elongated structural member 44. The first and second elongated structural members 42 and 44 define the space 52, which is substantially filled with a thermally insulative member 46 (not shown).

FIG. 16 is a perspective view of a ninth preferred embodiment of the thermally-insulative member of the present invention. The ninth embodiment is similar to the sixth preferred embodiment shown in FIG. 13, except that the first elongated structural member 42 is a C-channel with relatively short first and second legs 58 and 60. The first and second elongated structural members 42 and 44 define the space 52, which is substantially filled with a thermally insulative member 46 (not shown).

FIG. 17 is a perspective view of a tenth preferred embodiment of the thermally-insulative member of the present invention. The tenth embodiment is similar to the ninth preferred embodiment shown in FIG. 16, except that the second elongated structural member 44 is a C-channel with relatively short first and second legs 64 and 66. The first and second elongated structural members 42 and 44 define the space 52, which is substantially filled with a thermally insulative member 46 (not shown).

FIG. 18 is a perspective view of an eleventh embodiment of the thermally-insulative member of the present invention. The eleventh embodiment is similar to the tenth embodiment shown in FIG. 17, except that the first elongated structural member 44 engages the second elongated structural member 46 since the web 56 of the first elongated structural member 42 has a different dimension from that of the web 62 of the second elongated structural member 44, which is also a C-channel. This allows the legs of the C-channel having the shorter web to fit between the legs of the other C-channel. The first and second elongated structural members 42 and 44 define the space 52, which is substantially filled with a thermally insulative member 46 (not shown).

FIG. 19 is a perspective view of a twelfth embodiment of the thermally-insulative member of the present invention. The first and second elongated structural members 42 and 44 are conventional C-channel metal studs having respective webs 56 and 62. The first elongated structural member 42 also has first and second legs 58 and 60. However, the first leg 58 has an attached flange 90 which is substantially parallel to the web 56 and directed toward the second leg 60, but is substantially shorter than the web 56. Similarly, the second leg 60 has an attached flange 92 which is substantially parallel to the web 56 and directed toward the first leg 58, but is substantially shorter than the web 56. The second elongated structural member 44 is substantially identical to the first elongated structural member 42. It has respective flanges 94 and 96 that are attached to respective legs 66 and 64. The twelfth embodiment of the thermally-insulative member of the present invention is formed by placing the first and second elongated structural members 42 and 44 in contact, with respective flanges 90 and 96 of the first and second elongated structural members 42 and 44 aligned and in contact and with respective flanges 92 and 94 of the first and second elongated structural members 42 and 44 aligned and in contact. If desired, the flanges of the first and second elongated structural members 42 and 44 can be held together by fasteners or welding. The first and second elongated structural members 42 and 44 define the space 52, which is substantially filled with a thermally insulative member 46 (not shown).

FIG. 20 is a perspective view of a thirteenth embodiment of the thermally-insulative member 40′ of the present invention. The first elongated structural member 42′ is a conventional C-channel metal stud as described above in the description of FIG. 19. The second elongated structural member 44′ is the structure 40 described in FIG. 19. The flanges 90′ and 92′ of the first elongated structural member 42′ are attached to the web 56 of the second elongated structural member 44′. The first and second elongated structural members 42′ and 44′ define the space 52, which can be substantially filled with a thermally insulative member 46 (not shown). Alternatively, the space 52′ of the second elongated structural member 44′ can be substantially filled with a thermally insulative member 46 (not shown). As a further alternative, both of the spaces 52 and 52′ can be filled with a thermally insulative member 46 (not shown).

While the foregoing is a detailed description of the preferred embodiment of the invention, there are many alternative embodiments of the invention that would occur to those skilled in the art and which are within the scope of the present invention. In particular, the elongated structural members described in this application are an important, but small, part of those known to those skilled in the relevant arts. Further, the insulative materials and their manners of application that are described in this application are an important, but small, part of those known to those skilled in the relevant arts. Both the elongated structural members and the insulative materials and their manners of application described in this application are only illustrative. Accordingly, the present invention is to be determined by the following claims. 

1. An elongated stud for supporting a vertical load, comprising: a first elongated structural member having a vertical longitudinal axis; a second elongated structural member having a vertical longitudinal axis that is parallel to the vertical longitudinal axis of the first elongated structural member, the first and second elongated structural members being separated from each other and defining a space therebetween; and a thermally insulative member filling the space between the first and second elongated structural members, the thermally insulative member providing thermal insulation against heat flow in a horizontal direction.
 2. The stud of claim 1, wherein the first elongated structural member is a U-channel having a web and two legs extending therefrom and the second elongated structural member is a C-channel having a web and two legs extending therefrom.
 3. The stud of claim 2, wherein the legs of the U-channel extend toward the C-channel and the legs of the C-channel extend toward the U-channel.
 4. The stud of claim 3, wherein the legs of the U-channel are outward of the legs of the C-channel.
 5. The stud of claim 3, wherein the legs of the C-channel are outward of the legs of the U-channel.
 6. The stud of claim 1, wherein the thermally insulative member is made from a plastic material.
 7. The stud of claim 6, wherein the plastic material is polystyrene.
 8. The stud of claim 1, wherein the first and second elongated structural members touch.
 9. The stud of claim 1, wherein the first and second elongated structural members do not touch.
 10. A method for making an elongated stud for supporting a vertical load, comprising the steps of: a) forming a first elongated structural member having a vertical longitudinal axis; b) forming a second elongated structural member having a vertical longitudinal axis; c) placing the first and second elongated structural members so that their vertical longitudinal axes are parallel and there is a space defined therebetween; and d) filling the space between the first and second elongated structural members with a thermally insulative material thereby forming a thermally insulative member that provides thermal insulation against heat flow therethrough in a horizontal direction.
 11. The method of claim 10, wherein step a) comprises forming the first elongated structural member as a U-channel having a web and two legs extending therefrom and step b) comprises forming the second elongated structural member as a C-channel having a web and two legs extending therefrom.
 12. The method of claim 11, wherein step c) comprises placing the legs of the U-channel extending toward the C-channel and placing the legs of the C-channel extending toward the U-channel.
 13. The method of claim 12, wherein step c) comprises placing the legs of the U-channel outward of the legs of the C-channel.
 14. The method of claim 13, wherein step c) comprises placing the legs of the C-channel outward of the legs of the U-channel.
 15. The method of claim 11, wherein step d) comprises filling the space between the first and second elongated structural members with a thermally insulative plastic material.
 16. The method of claim 15, wherein the plastic material of step d) is polystyrene.
 17. The method of claim 11, wherein step c) comprises placing the first and second elongated structural members so that they touch.
 18. The method of claim 11, wherein step c) comprises placing the first and second elongated structural members so that they do not touch.
 19. An apparatus for making an elongated stud for supporting a vertical load, comprising: means for forming a first elongated structural member having a vertical longitudinal axis; means for forming a second elongated structural member having a vertical longitudinal axis; means for placing the first and second elongated structural members so that their vertical longitudinal axes are parallel and there is a space defined therebetween; and means for filling the space between the first and second elongated structural members with a thermally insulative material thereby forming a thermally insulative member that provides thermal insulation against heat flow therethrough in a horizontal direction.
 20. The apparatus of claim 19, wherein the means for forming the first elongated structural member forms a U-channel having a web and two legs extending therefrom and the means for forming the second elongated structural member forms a C-channel having a web and two legs extending therefrom.
 21. The apparatus of claim 20, wherein the means for placing places the legs of the U-channel extending toward the C-channel and places the legs of the C-channel extending toward the U-channel.
 22. The apparatus of claim 21, wherein the means for placing the first and second elongated structural members places the legs of the U-channel outward of the legs of the C-channel.
 23. The apparatus of claim 22, wherein the means for placing the first and second elongated structural members places the legs of the C-channel outward of the legs of the U-channel.
 24. The apparatus of claim 20, wherein the means for filling the space fills the space between the first and second elongated structural members with a thermally insulative plastic material.
 25. The apparatus of claim 24, wherein the means for filling the space fills the space between the first and second elongated structural members with polystyrene.
 26. The apparatus of claim 19, wherein the means for placing places the first and. second elongated structural members so that they touch.
 27. The apparatus of claim 19, wherein the means for placing places the first and second elongated structural members so that they do not touch. 